My FCSP (Ford Charge Station Pro) works great with no shutdowns due to overheating. Does yours?

PiMatrix · Jul 25, 2022

This thread is dedicated to those who have no thermal shutdowns or error messages. I've seen some posts that suggest things are working normal for a couple of people. If this is true it is a good sign that needs explored. Please post here if you are one of those and provide some details if you can - gauge wire, indoor, outdoor location, environment temperature. Also if you've derated your charger to something less than 80A, e.g. 64 with no issues. Anything different about your install, when you received the charger? Even if it's a very rare occurrence to see a shutdown at 80A that is noteworthy.

Tony Burgh · Jul 26, 2022

As I posted before, no problems at this end. I can charge at all hardware dial settings and any software settings. For software settings I have charger dial at position 7. I have 100 amp breaker in panel and connect to the charger with three 2 gauge wires. The electrical runs and connections were made by a licensed electrician. The charger is mounted on a wood frame bolted into a brick on concrete block foundation exterior wall. The wall faces northeast and receives direct sun in summer months. Ambient highs have been in the high 80’s to mid 90’s for past month. I don’t charge until SoC gets down to 20% or so. Charge upper limit set to 90% through interface in the truck. I currently have the current set at 64 amps through Ford app. I connect with iPhone and 2.4 wifi through a wifi extender (Netgear). My favorite color is blue.

FlasherZ · Jul 26, 2022

Tony Burgh said:
My favorite color is blue.

Atlas Blue or Ice Blue or Lightning Blue or Navy Blue or ...?

Seriously, you've said any hardware and software settings... have you been setting your charge current to 64A mostly since the start, or did you do a lot of charging at the full "80A"?

I haven't driven my truck far enough since installation this weekend to give it a good long time to charge and warm up.

And what does FordPass say your software level is at? (FordPass -> Account -> Charge Station -> Settings -> EVSE Software Version)

Tony Burgh · Jul 26, 2022

Only once at full 80 amp setting (measured 77 amps on blue and brown wires in charger). My home has only 150 amp service (natural gas furnace, hwh and cook surface) from 20 years ago. Not much added draw at 80 versus 64 but thought I’d stay below half max. When I charge again next I’ll go to full 80 setting again since it’s an easy software change without opening the box again.
Version 4.18.0 USA

FlasherZ · Jul 26, 2022

Tony Burgh said:
Only once at full 80 amp setting (measured 77 amps on blue and brown wires in charger). My home has only 150 amp service (natural gas furnace, hwh and cook surface) from 20 years ago. Not much added draw at 80 versus 64 but thought I’d stay below half max. When I charge again next I’ll go to full 80 setting again since it’s an easy software change without opening the box again.
Version 4.18.0 USA

I'd be curious to see whether you get the cycling after 20-30 mins at the full 80A setting.

That doesn't appear to be the right software version.

This is what we should look at:

Ford F-150 Lightning My FCSP (Ford Charge Station Pro) works great with no shutdowns due to overheating. Does yours? Screenshot_20220726-075651_FordPass~2

Tony Burgh · Jul 26, 2022

Ford F-150 Lightning My FCSP (Ford Charge Station Pro) works great with no shutdowns due to overheating. Does yours? 1E0393F0-B0D1-41E5-B5B5-2CD525DBD67B

Tony Burgh · Jul 26, 2022

I guess I joined the club today. Figured I’d try again even though SoC was 76%.
I now have a cycling charge session.
Only difference from before is that the charger cover is on. It must be off for current measurement which I’m not doing now.

Ford F-150 Lightning My FCSP (Ford Charge Station Pro) works great with no shutdowns due to overheating. Does yours? 50E7601F-2C42-4609-8AD4-033E107A4595

PiMatrix · Jul 26, 2022

Thank you for the data point. So to be clear, when you were able to charge at 76-80amp you had cover off as you were doing some current measurements. But now that cover is sealed tight you are seeing the thermal shutdowns and restart? I know Ford was pushing a firmware change that would throttle the charging current to keep below complete shutdown. Is that what you posted above as I don't see error messages?

#2 wire was intriguing as I know another person who was not getting shutdowns with #2 which implied that the thicker wire itself was helping to pull excess heat out of contactor area. But I guess not...

Blue for me too!

FlasherZ · Jul 26, 2022

PiMatrix said:
I know Ford was pushing a firmware change that would throttle the charging current to keep below complete shutdown. Is that what you posted above as I don't see error messages?

Look at his charge logs - the unit delivers just over 1 kWh then stops and restarts... that's a sign of the problem.

As for the software, both he and I have the same version - 2.112.64 - and I'll keep an eye on it for an upgrade over the next week or so.

Note that for whatever reason, the Charge Station Pro will never charge at 80A... it's only advertising 76-78 amps to the truck (94.5% duty cycle on the J1772 pilot signal).

PiMatrix · Jul 26, 2022

So, to date, is it fair to say 100% of the chargers seem to have this thermal issue? If there is even one that works at even 76A under all conditions it would be very interesting. It was telling that he was able to operate at full current without the cover on using natural convection. So there is some glimmer of hope for a natural convection hole approach... I'm thinking strategically place top and bottom (with screen to prevent buggers) to create a chimney cooling effect. But no NEMA so not outdoor solution.

Tony Burgh · Jul 26, 2022

No problem charging at almost 80 amps with cover OFF. There should be a way to vent heat from the charger with the cover on and still meet code for the charger. TEFC like electrical motors?

PiMatrix · Jul 26, 2022

Yes, a strategically placed watertight heat sink perhaps integrated into the top cover with integrated fan might do the trick and keep NEMA rating. Even a heat pipe passive heat sink might work. A few holes top and bottom might be easiest approach for indoor use only. I'm sure the issue is solvable with a little engineering. It sounds like many manufacturers including Tesla have had some trouble with heat in these high current chargers. The good news is that 64A or a throttled charge, while a bit disappointing, probably meets the need of an overnight charge so not a show stopper while they figure it out. Maybe there needs to be two models where sealed NEMA cover costs a bit more as that seems to be predominant challenge: Heat In > Heat Out => Temp rise => safety shutdown

Being on the forefront of technology always brings joys and risks.

ooSHAZAMoo · May 24, 2023

I see my FSCP firmware is out of date. How do I update it?

tk44189 · May 24, 2023

Mines inside. 60ft run of 2ga copper wire with 6ga earth. Runs great. Never an issue here

Pioneer74 · May 24, 2023

ooSHAZAMoo said:
I see my FSCP firmware is out of date. How do I update it?

Cycle the power to it and leave your truck unplugged overnight. It will update on its own.

My FCSP (Ford Charge Station Pro) works great with no shutdowns due to overheating. Does yours?

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